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U.S. Boiler Company SERIES 3 Installation, Operating And Service Instructions

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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR
9700609
For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide
Boiler Model Number and Serial Number as shown on Rating Label.
Boiler Model Number
30__B
Heating Contractor
Address
103796-04 - 3/13
SERIES 3™
Gas - Fired Boiler
Boiler Serial Number
Installation Date
Phone Number
Price - $5.00

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Summary of Contents for U.S. Boiler Company SERIES 3

  • Page 1 INSTALLATION, OPERATING AND SERVICE INSTRUCTIONS FOR SERIES 3™ Gas - Fired Boiler 9700609 For service or repairs to boiler, call your heating contractor. When seeking information on boiler, provide Boiler Model Number and Serial Number as shown on Rating Label.
  • Page 2 WARNINGS FOR ThE hOMEOWNER outdoor temperatures are below 32°F, first turn off FOLLOW ALL INSTRUCTIONS and warnings printed in this manual and posted on the boiler. your home’s main water supply and drain the water from all pipes. INSPECT THE BOILER ANNUALLY. To keep your boiler safe and efficient, have a service technician DO NOT BLOCK AIR FLOW into or around the follow the Service checklist near the end of this...
  • Page 3 • System-friendly – built-in protection from condensation and thermal shock. IQ Control System Overview Series 3 Boiler uses a microprocessor based control system called the "IQ Control System". This "IQ Control System" consists of an Intelligent Hydronic Control (Control) and an IQ Option Panel (Option Panel) with optional "plug-in"...

  • Page 4: Specifications

    SPECIFICATIONS Ratings Series 3 Input (MBH) DOE Heating Capacity (MBH) Net AHRI Rating (MBH) AFUE (%) Boiler Model 303B 304B 305B 306B 307B 308B 309B Electrical Requirements: 120VAC, 60 hz, 1-ph, 15A Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi relief valved.
  • Page 5 SPECIFICATIONS (continued) Figure S-1: Minimum Clearances to Combustibles and Alcove Dimensions...

  • Page 6: Table Of Contents

    BOILER QUICk-START Installation: Unpack the crate ..................... 7 Position the boiler .................... 8 Provide combustion air ..................9 Connect venting ....................9 Connect gas piping ..................10 Connect boiler water piping ................10 Connect electrical wiring ................12 Program the controls ..................13 Check for gas and water leaks ..............

  • Page 7: Unpack The Crate

    1. UNPACk ThE CRATE THE BOILER IS TOP-HEAVY. Do not Tip the boiler and shimmy it off the skid (Figure 1-b). allow it to tip over. Remove the sleeve. Remove the contents from the skid, except the boiler. Remove the four (4) hex-drive lag screws holding the boiler to the skid (Figure 1-a).

  • Page 8: Position The Boiler

    2. POSITION ThE BOILER WARNINGS OBSERVE MINIMUM CLEARANCES to CLEAN BURNERS DAILY if operating the boiler in combustible walls and ceilings to avoid potential a dusty environment. fire hazard. PROTECT IGNITION SYSTEM COMPONENTS DO NOT INSTALL ON CARPET. This may cause from sources of water that may spray, drip, or rain a fire.

  • Page 9: Provide Combustion Air

    3. PROVIDE COMBUSTION AIR Like all fuel-burning appliances, boilers need air to INSUFFICIENT COMBUSTION AIR SUPPLY may result in the production and operate reliably and safely. release of deadly carbon monoxide (CO) into the Provide combustion air using the instructions in home which can cause severe personal injury or Appendix A—Combustion Air.

  • Page 10: Connect Gas Piping

    5. CONNECT GAS PIPING Size gas piping according to Appendix C – Gas nipples and street ells are not approved for Piping use as gas piping. SHUT OFF GAS SUPPLY before Pipe through the left jacket panel, and servicing the boiler. complete drip leg as shown (Figure 5-a).
  • Page 11 6. CONNECT BOILER WATER PIPING (continued) Screw an installer-supplied 1¼” pipe or See Figure 6b for suggested near boiler nipple into the water return tapping “R”. piping of IQ Options. Screw the supplied drain valve into tapping “D”. Item Description Part Number 1¼...

  • Page 12: Connect Electrical Wiring

    7. CONNECT ELECTRICAL WIRING DISCONNECT ELECTRICAL POWER to the boiler and heating system before servicing. Positively assure that no voltage is present. Lock electrical boxes to prevent someone from inadvertently restoring power before the heating system is safe to operate. NEVER DEFEAT OR JUMP OUT safety devices.

  • Page 13: Program The Controls

    8. PROGRAM ThE CONTROLS Using Intelligent Hydronic Control Display . Press and release the “I” key on the control to change from one parameter to The Intelligent Hydronic Control (control) is located the next. Each setting will alternately flash inside the boiler front door, just above the IQ between the relevant display code and its Option Panel (Figure 8-a).
  • Page 14 8. PROGRAM ThE CONTROLS (continued) The Outdoor Reset IQ Option Card reduces Please note that in operating mode to hold the display on the value the user can press and hold the Operating Setpoint to regulate heat either the Up ñ or Down ò keys and the value delivery, increase home comfort and will be continuously shown.
  • Page 15 8. PROGRAM ThE CONTROLS (continued) Domestic Hot Water (DHW) Terminal Table 8a: Circulator Pre-purge Time example, Function (dh_) (PP_ = 2 minutes) The control allows configuration of the Call for DHW Circulator output functionality to help Boiler Heat Terminal Burner Status Temperature the Boiler integrate into each installation Source...

  • Page 16: Check For Gas And Water Leaks

    8. PROGRAM ThE CONTROLS (continued) b. When dh_ is set equal to Second Heating Using the IQ Option Panel Zone (tt2) IQ Option Cards are available from U.S. Boiler When there is no IWH the “DHW Company distributors and are the simplest way Circulator”...

  • Page 17: Perform Startup Checks And Adjustments

    10. PERFORM STARTUP ChECkS AND ADjUSTMENTS FAILURE TO PERFORM THESE CHECKS of the boiler's combustion and safety systems may result in serious property damage, injury, or death. IF YOU SMELL GAS, STOP and repair the leak. Lighting the boiler when gas is leaking may cause explosion or fire.

  • Page 18: Annual Maintenance Checklist

    ANNUAL MAINTENANCE ChECkLIST WARNINGS personal injury or death, and extensive property THE BOILER CONTAINS REFRACTORY CERAMIC FIBER, a possible human carcinogen damage. Use a NIOSH approved respirator when servicing TURN OFF ALL GAS AND ELECTRIC power high-temperature insulation and gasket materials. supplies to the boiler before servicing.

  • Page 19: Troubleshooting

    TROUBLEShOOTING wiring diagram in Figures IW-1 and IW-2. Before troubleshooting Ensure that incoming 120 Vac power polarity The following pages contain trouble shooting is correct and that the boiler is properly tables for use in diagnosing control problems. grounded. Further, ensure that the control When using these tables the following should power supply is 24 VAC (minimum 18 VAC be kept in mind:...
  • Page 20 TROUBLEShOOTING (continued) Use Control Display ERR (error) Number To Direct Troubleshooting Efforts If the control detects an error it will flash “Err” (error) followed by a number. Use this number to identify the boiler problem and corrective action in the table below. If there is no Err display proceed to next Section: Display Status...
  • Page 21 TROUBLEShOOTING (continued) Use STA (status) Number To Guide Troubleshooting The control will flash “STA” followed by a number. Use this number to identify the boiler problem in the table below: 1. Boiler and Circulator Off Display / Status Recommended Corrective Action The boiler has not detected a call for heat (tt = off and dh = off).
  • Page 22 TROUBLEShOOTING (continued) 5. Circulator is On But Damper is Not Open Display / Status Recommended Corrective Action The control is waiting for the damper to open. Damper end switch has failed to close (end switch contact is stuck open). Combustion can never take place unless the damper blade is in the fully open position. Check the following: - During status “STA18"...
  • Page 23 TROUBLEShOOTING (continued) Display / Status Recommended Corrective Action 1. No Spark a. Can you hear sparking while STA 6 is displayed? - If there is no spark noise replace the control. b. If you can hear spark noise check the following: - Loose connection in ignition cable or ground wire - Continuity of ignition cable - Break in ignition cable insulation...
  • Page 24 TROUBLEShOOTING (continued) If Control Shows Status Code “STA 15": The control is “Waiting for Limit to Close” and the display on the IQ Option Panel should be the first place to check. The IQ Option Panel display (lower display) will show one of the following status codes: IQ Option Panel Display Shows “ERR"...

  • Page 25: Repair Parts List

    REPAIR PARTS LIST [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Block Assembly 102287-03 102287-04 102287-05 102287-06 102287-07 102287-08 102287-09 Canopy Gasket Kit 6206001 Canopy Assembly 102554-03 102554-04 102554-05 102554-06 102554-07 103860-08 102554-09 Blocked Vent Switch 80160157 (not shown)
  • Page 26 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Base Wrapper 71807031 71807041 71807051 71807061 71807071 71807081 71807091 Base Tray 102543-03 102543-04 102543-05 102543-06 102543-07 102543-08 102543-09 Burner Tray Assembly 61807031 61807041 61807051 61807061 61807071 61807081 61807091...
  • Page 27 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Gas Valve (Natural Gas), 81660282 Honeywell VR8204P1171 Gas Valve (Natural Gas), 81660283 Honeywell VR8304P4496 Gas Valve (LP Gas), Honeywell 81660146 VR8204C3015 Gas Valve (LP Gas), Honeywell 81660160 VR8304P4314 ½"...
  • Page 28 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Control 103660-01 IQ Option Panel 102291-01 Transformer 102516-01 Temperature Sensor 102411-01 Temperature Sensor Spring Clip (not shown) 102422-01...
  • Page 29 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Jacket Left Side Panel 102566-01 Jacket Right Side Panel 102567-01 Jacket Rear Panel 102569-03 102569-04 102569-05 102569-06 102569-07 102569-08 102569-09 Jacket Vestibule Panel 102565-03 102565-04 102565-05 102565-06 102565-07...
  • Page 30 REPAIR PARTS LIST (continued) [Quantity] Part Number Description 303B 304B 305B 306B 307B 308B 309B Supply Water Manifold 80607001 Temperature/Pressure Gauge 100282-01 30 PSI Relief Valve 81660363 Drain Valve 102802-01 Vent Damper 102284-01 102284-02 102284-03 102284-04 102284-05 Circulator (not shown): Taco 007-2 8056170 Grundfos UP-15...

  • Page 31: Internal Wiring

    INTERNAL WIRING Figure IW-1: Wiring Diagram...
  • Page 32 INTERNAL WIRING (continued) Figure IW-2: Wiring Schematic...
  • Page 33 INTERNAL WIRING (continued) Figure IW-3: Multiple Zone System with Zone Circulators Figure IW-4: Multiple Zone System with Zone Valves...
  • Page 34 INTERNAL WIRING (continued) Figure IW-5: Multiple Zone System with Zone Circulator Panel DHW AQUASTAT (L4006, L4080) POWER (SUPPLIED BY OTHERS) SUPPLY 120/60/1 THERMOSTAT THERMOSTAT THERMOSTAT TRANSFORMER DOMESTIC HOT WATER PRIORITY IS SELECTED USING ZONE PANEL SWITCH MODE ZONE 4 PRIORITY NORMAL RESET IQ OPTION PANEL POWER IN...

  • Page 35: A - Combustion Air

    APPENDIX A – COMBUSTION AIR If the Floorspace from Step 1 is less than the PROVIDE ENOUGH AIR to ventilate the Minimum Floorspace from Step 3, then you boiler room, dilute the flue gases, and must provide outdoor air to the boiler room. sustain combustion.

  • Page 36: B - Venting

    APPENDIX B – VENTING VENT THIS BOILER according to the instructions. Failure to do so may cause products of combustion to enter the building resulting in severe property damage, personal injury or death. Install this boiler according to this manual and the National Fuel Gas Code, ANSI Z223.1/NFPA 54, the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.
  • Page 37 APPENDIX B – Venting (continued) Au moment du retrait d’une chaudière Une fois qu’il a été déterminé, selon existante, les mesures suivantes doivent la méthode indiquée ci-dessus, que être prises pour chaque appareil toujours chaque appareil raccordé au système raccordé au système d’evacuation d’évacuation est mis à...
  • Page 38 APPENDIX B1 – ATMOSPhERIC VENTING GENERAL WARNINGS FOR ATMOSPhERIC VENTING SYSTEMS DO NOT REDUCE THE DIAMETER of the vent USE ATMOSPHERIC VENTING only with boilers approved for atmospheric venting as connector between the boiler and the chimney. It noted in the Specifications Section of this must not be smaller than the outlet on the draft hood, damper, or vent reducer supplied with the manual.
  • Page 39 APPENDICE B1 – SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPhÈRE AVERTISSEMENTS GÉNÉRAUX POUR LES SYSTÈMES D’ÉVACUATION DES PRODUITS DE LA COMBUSTION DU GAZ DANS L’ATMOSPhÈRE NE PAS RÉDUIRE LE DIAMÈTRE du conduit N’ÉVACUEZ LES PRODUITS DE LA d’évacuation des produits de la combustion du gaz COMBUSTION DU GAZ DANS L’ATMOSPHÈRE que dans le cas de chaudières approuvées pour...

  • Page 40: C - Gas Piping

    APPENDIX C – GAS PIPING Table C-3: Specific Gravity Correction Factors For ASSURE GAS PIPING IS LEAK FREE Natural Gas AND OF PROPER SIZE and type for the connected load. Specific Specific Correction Correction Gravity Factor Gravity Factor SHUT OFF MAIN GAS SUPPLY prior to installing or servicing boiler gas piping.

  • Page 41: D - System Piping

    APPENDIX C – Gas Piping (continued) Bond all above-ground gas piping to a When testing at ½ psig or less, isolate grounding electrode and ensure the piping is boiler from gas supply piping by closing electrically continuous. boiler’s individual manual shut-off valve. Locate leaks using approved DO NOT USE GAS PIPING AS A combustible gas detector or...
  • Page 42 APPENDIX D – System Piping (continued) Overpressure temperature requirements. Install a boiler bypass, system bypass, or Install a properly sized expansion tank. primary-secondary loop when needed to Do not exceed the boiler’s specific maintain water temperatures and flows requirements for maximum allowable within the specified limits.

  • Page 45: E - Filling The System And Checking For Leaks

    APPENDIX E – FILLING ThE SYSTEM AND ChECkING FOR LEAkS Fill entire heating system with water and vent air from system. Use the following procedure on a Series Loop or multi-zoned system installed as per the figure below. Remove air from system when filling. Close full port ball valve located between Open the zone valve or shut-off valve vertical hose bib and air scoop in boiler...

  • Page 46: F - Adjusting Gas Input Rate

    APPENDIX F – ADjUSTING GAS INPUT RATE Check Manifold Pressure: Note the rated manifold gas pressure listed on the boiler’s rating label. Connect Manometer to manifold pressure tapping on Gas Valve (Figure F-1). Light main burners by adjusting thermostat to highest setting. DO NOT EXCEED the boiler’s rated gas input.

  • Page 47: G - Checking Draft And Combustion

    APPENDIX G – ChECkING DRAFT AND COMBUSTION CHECK DRAFT (GAS BOILERS WITH DRAFT HOODS) After 5 minutes of main burner operation, Insofar as is practical, close all doors and test for spillage at the draft hood relief windows in the building. opening, using a lighted match, candle, Turn on all appliances not connected to the cigarette, etc.

  • Page 48: H - Operation

    APPENDIX h – OPERATION Boiler Sequence of Operation Table 4: Sequence of Operation NORMAL OPERATION Status Codes displayed in STA Mode The boiler is equipped with an Intelligent Status Description Hydronic Control (control). This control Standby replaces the traditional separate ignition (Burner off No call for heat detected control, high limit switch and circulator relay...

  • Page 49: I - Iq Control System

    APPENDIX I – IQ CONTROL SYSTEM • Ensures adequate heat and supply of IQ Control System Overview domestic hot water. The “IQ Control System” consists of a control and • UL / CSA Listed or Recognized and tested an IQ Option Panel with optional “plug in” cards: as part of a complete system.
  • Page 50 APPENDIX I – IQ Control System (continued) IQ Outdoor Reset Option Card: P/N 102723-01 Installing the IQ Outdoor Reset Option Card is the simplest way to maximize the efficiency of any boiler. The IQ Outdoor Reset Card is a microprocessor- based control that regulates the water temperature of the heating system based on the outdoor temperature.
  • Page 51 APPENDIX I – IQ Control System (continued) IQ Hi Limit Option Card (Auto Reset): P/N 102717-01 IQ Hi Limit Option Card (Manual Reset): P/N 102720-01 IQ High Limit Option Cards add auxiliary temperature limit-rated controls to boilers. High Limit Option Cards plug into the IQ Option Panel and connect to a system-mounted probe with a single Molex connection.
  • Page 52 APPENDIX I – IQ Control System (continued) stem Parts List Optional Components Part Number Item Description Outside Reset IQ Option Card, Domestic Hot Water Priority, for use with Option Control Panel, with Outside 102723-01 Air Temperature Sensor with 60 inch lead, Instructions, Unit Pack. No additional pipe fittings required. 102294-01 Outdoor Reset IQ Option Card, Domestic Hot Water Priority, for use with IQ Option Panel, less Sensor.
  • Page 53 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 54 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 55 SERVICE RECORD DATE SERVICE PERFORMED...
  • Page 56 U.S. Boiler Company, Inc. P.O. Box 3020 Lancaster, PA 17604 1-888-432-8887 www.usboiler.net...

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